Hip, ridge, and valley construction clip

ABSTRACT

A clip to be used with at least one track in a roofing assembly, the clip including a planar surface and at least one pair of flanges extending away from the planar surface in an orthogonal manner to define a right angle between each flange and the planar surface. Each flange defines an attachment surface for a corresponding track and extends away from a lower boundary of the planar surface in an orthogonal manner to define a right angle between each flange of the upper pair of flanges and the planar surface. The clip is sized to form a roof assembly having a pitch selected from any one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12. Moreover, the planar surface may include a G-90 coating and the clip can be manufactured from a material selected from a group including 16 gauge steel, wood, polymer and an alloy.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/802,140, filed May 22, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a hip, ridge and valley constructionclip used to facilitate creation of roof assemblies for residential andcommercial structures.

2. Description of the Related Art

Typically, present day home and commercial construction techniques donot always lend themselves to a truss support system. While trusssupport systems continue to be used in roofing systems having relativelysimple or conventional designs, many new building structures call forcustom roofing systems. Therefore, such custom roofing systems includeroof designs that require what is commonly referred to as a rafterframe. Builders or roofing contractors often approach such rafter frameswith reluctance in terms of devising a methodology and assembly forconstructing the roofing system, particularly when the roofing systemrequires the use of light gauge steel.

In conventional wooden roof framing, builders or roofing contractorscommonly use a ridge beam. When the ridge beams are required to be usedwith light gauge steel, the rafters of the roofing system must be cut onan angle of the roof, which requires an inordinate number of clips.

As a result, there is a need in the construction industry, andparticularly in the roofing industry, for a clip that saves time andmaterial, and as a result, provides significant cost savings to roofframers, builders, and building owners. Moreover, light gauge steelframing becomes a more economically viable and effective constructionoption.

SUMMARY OF THE INVENTION

It is an aspect of the present invention to provide a hip, ridge andvalley clip (hereinafter, simply referred to as an “HRV clip” or a“clip”) that is configured to make it easier to construct rafter roofframes from light gauge steel. The clip is primarily intended to be usedby the light gauge steel industry for residential housing and smallcommercial construction markets. The clip is to be used to createassemblies, such as, hip assemblies, ridge assemblies and valleyassemblies in the construction of light gauge steel roofing systems.

According to one feature of the present invention, the clip ismanufactured from galvanized steel sheets of a light gauge, e.g., 16gauge, having a G-90 coating on at least one, and preferably both sides.A template or pattern is formed for each clip and is used as a guideduring the production process. The clip is produced by shearing themetal sheet into the correct pattern and then subjecting the shearedmetal sheet into the appropriate pattern using a suitable piece ofmanufacturing equipment, e.g., a break press.

Preferably, the metal sheet is a substantially square piece of metalafter having been sheared during the production process. The largersized clips are typically modified to have tapered edges so as to allowthe break press to fold the sheet to finalize the clip productionprocess. It should be noted that breaking the metal sheet to form theclip creates flanges that are bent approximately 90 degrees in adirection toward the rear face of the clip. The flanges serve asattachment faces to which the tracks of the roofing system are attachedto create a roof assembly.

Another feature of the present invention is that the clip can bedesigned to fit the pitch of any roof, such that the larger the roof,the larger the size of the clip. In other words, the dimensions of theclip of the present invention are proportional relative to the pitch ofthe roof such that the size, and even material choice, of the clip maybe adjusted accordingly.

Preferably, the clip is inserted between a pair of tracks to create anassembly that can be used for any one of hips, ridges or valleys. Asdescribed above, conventional wood framing requires the use of a ridgebeam, wherein when the ridge beams are used with light gauge steel, therafters must be cut to the angle of the roof, which requires not onlythe step of cutting the rafter, but also requires a rather high numberof clips. The clip of the present invention eliminates not only thecostly and time consuming step of cutting the rafter to the preciseangle of the roof pitch, but also substantially reduces the number ofclips that must be used in the roofing assembly.

Once the clip is positioned between the pair of tracks to create anassembly, the assembly is set in place within the roofing system and therafters are placed inside the track and connected to a top portion andbottom portion of the flange for each corresponding track using,preferably, mechanical fasteners. No additional clips are required, butmost importantly, the rafters do not have to be cut before attaching therafters to the clip and tack assembly. Accordingly, the clip of thepresent invention provides or creates the pitch needed by the builder sothat the builder may use the materials, e.g., rafters, tracks, and thelike, as provided by the manufacturer without any further modificationsmade to the materials in the field. As such, the clip of the presentinvention saves the builder a significant amount of time spent onerecting or constructing the roof.

The clip of the present invention provides several advantages that wouldreadily be understood to one of ordinary skill in the art to which theinvention pertains. For example, once positioned inside or between thepair of tracks, the clip and tracks create or define an assembly thatcan be manufactured to any length. Furthermore, unlike the long beamsused in conventional roof framing systems, the weight of the clip andtracks assembly is very lightweight and can easily be handled by thebuilders in the field. Moreover, as stated above, the inventive clip canbe used with any roof pitch. As a result, the assembly using theinventive clip and pair of tracks saves the builder significant sums oftime and money by eliminating the need to cut the rafters to the preciseangle and the number of clips needed.

The above and other aspects, features and advantages of the inventionwill become apparent from the following description of preferredembodiments taken in conjunction with the accompanying drawings andappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is front view of a sheet of material on which a pattern isprovided to form the inventive clip according to an embodiment of thepresent invention;

FIG. 2 is front view of the sheet of material from FIG. 1 after theupper left and right flanges have been bent away from a first surface ofthe sheet;

FIG. 3 is front view of the sheet of material from FIG. 2 after thelower left and right flanges have been bent away from a first surface ofthe sheet;

FIG. 4 is front view of the sheet of material from FIG. 3 after trackshave been attached to the surfaces of the lower left and right flangesafter the flanges have been bent away from a first surface of the sheet;

FIGS. 5 a-c illustrate another embodiment of the inventive clip, whichis designed for a roof having a 6/12 pitch;

FIGS. 6 a-c illustrate another embodiment of the inventive hip andvalley clip, which is designed for a roof having a 6/12 pitch;

FIGS. 7 a-c illustrate another embodiment of the inventive clip, whichis designed for a roof having a 7/12 pitch;

FIGS. 8 a-c illustrate another embodiment of the inventive hip andvalley clip, which is designed for a roof having a 7/12 pitch;

FIGS. 9 a-c illustrate another embodiment of the inventive clip, whichis designed for a roof having a 8/12 pitch;

FIGS. 10 a-c illustrate another embodiment of the inventive hip andvalley clip, which is designed for a roof having a 8/12 pitch; and

FIGS. 11-14 illustrate alternate embodiments of the inventive clip.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a description of a preferred embodiment of thepresent invention will be discussed. The hip, ridge and valley clip 1(hereinafter interchangeably referred to as the “HRV clip” or simply the“clip”) is formed from a sheet of material 10, which is preferablymetal, but can also be any suitable material possessing sufficientstrength and other properties to be used in a roofing system. Suchmaterial as polymer, wood, alloy, and other materials that are now knownor later developed are to be considered within the scope of the presentinvention. Put simply, the type of material chosen from which the clip 1is to be manufactured should be left to the engineer, architect,designer or builder of the roofing system based on the requirements andneeds of the roofing system.

It should be noted that if the material is steel, preferably the steelis a light gauge steel, and even more preferably, is a 16 gauge steel.Moreover, at least one, and preferably both, surface(s) of the sheet ofmaterial is provided with a G-90 coating.

A pattern or boundary 11(11 a and 11 b) is provided on a first surface 2of the material 10 which defines a pentagon shape and segments the firstsurface 2 into four flanges 12 through 15 and a center region 16. Thepattern 11 segments the first surface 2 into upper left and rightflanges 12 and 13, respectively, lower left and right flanges 14 and 15,respectively, and the center region 16. The upper left and right flanges12 and 13 are each defined by a corresponding upper boundary 11 a of thecenter face 16, while the lower left and right flanges 14 and 15 areeach defined by a corresponding lower boundary 11 b of the center face16.

To arrive at the clip 1, the material 10 is first sheared from a largersheet of material (not shown) such that a relatively square shaped pieceof material 10 remains. The pattern 11 is then provided on the firstsurface 2 of the material 10 so as to segment the first surface 2 intofour flanges 12 through 15 and a center region 16. A break press (notshown) is then used to bend the material 10 along the pattern 11 so asto define each flange 12 through 15 and the center region 16.

For example, as shown in FIG. 2, the break press bends the material 10along the upper boundary 11 a of the center face 16 such that the upperleft and right flanges 12 and 13, respectively, are extending away fromfirst surface 2. The upper left and right flanges 12 and 13 shouldextend away from the first surface 2 by at least 90 degrees, andpreferably extend away from the first surface 2 exactly 90 degrees toform a right angle with the center region 16. As such, when viewing thefirst surface 2 as seen in FIG. 2, the flanges 12 and 13 should not bevisible to the observer as they are extending into the sheet of paper.

The break press (not shown) is then used to bend the material 10 alongthe pattern 11 so as to define each lower left and right flange 14 and15. For example, as shown in FIG. 3, the break press bends the material10 along the lower boundary 11 b of the center face 16 such that thelower left and right flanges 14 and 15, respectively, are extending awayfrom first surface 2. The lower left and right flanges 14 and 15 shouldextend away from the first surface 2 by at least 90 degrees, andpreferably extend away from the first surface 2 exactly 90 degrees toform a right angle with the center region 16. As such, when viewing thefirst surface 2 as seen in FIG. 3, the flanges 14 and 15 should not bevisible to the observer as they are extending into the sheet of paper.Moreover, the resulting clip 1 will preferably have a pentagon shapedefined by the two upper boundary lines 11 a, 11 a, the two lowerboundary lines 11 b, 11 b, and a third boundary 11 c formed between thetwo lower boundary lines 11 b, 11 b.

The flanges 12 through 15 are configured to receive a track thereon soas to form a roof assembly into which a plurality of rafters (not shown)may be inserted. For example, looking at FIG. 4, a track TR1 is placedagainst the lower left flange 14 and attached thereto by a fastener (notshown), which can be any well known or later developed fastener, such asa bolt, screw, nail, and the like. It is also within the scope of theinvention for the track TR1 to be affixed to the lower left flange 14using an adhesive or other such industrial strength adhesive, as well asany known or later developed welding technique. Similarly, another trackTR2 is placed against the lower right flange 15 and similarly attachedor affixed thereto. At least one rafter (not shown), and most likely aplurality of rafters, are then inserted into the open end of each trackTR1 and TR2, so as to provide an assembly component of a roofing system.

The preferred embodiment of the clip 1 anticipates the use of 6 inchrafters within the open end of each track TR1 and TR2. However,modifications may be made to the clip 1 to change the pitch of the roof.For example, if the material used for the rafters exceeds 6 inches, thenthe dimensions of the clip 1 may also change accordingly. In otherwords, the dimensions of the clip 1 are all proportional to the pitch ofthe roof, such that the overall size of the material 10 used will changeaccordingly.

The inventive clip 1 of the instant application is intended to be usedwith any known roof pitch. For example, FIG. 5 a illustrates anotherembodiment of the inventive clip wherein a clip 21 is used for roof thatis on a 6/12 pitch. A difference between the clip 21 of FIG. 5 a and theclip 1 of FIGS. 1-4 is the size of the clip 21 results in smaller upperleft and right flanges 22 and 23, being formed, and larger lower leftand right flanges 24 and 25. Moreover, each of the lower left and rightflanges 24 and 25 includes a tapered edge 24 a and 25 a, respectively,to facilitate being bent by the break press or machine. FIG. 5 b shows alower left perspective view of the clip 21 while FIG. 5 c shows an upperleft perspective view of the clip 21.

In another example, FIG. 6 a illustrates another embodiment of theinventive clip wherein a 6/12 hip and valley clip 31 is used for roofthat is on a 6/12 pitch. A difference between the clip 31 and the clip 1of FIGS. 1-4 is the size of the upper left and right flanges of the clip31 are smaller than the upper left and right flanges 12 and 13 of theclip 1. Also, a difference between the clip 31 of FIG. 6 a and the clip21 of FIGS. 5 a-c is that the lower left and right flanges 34 and 35 ofthe clip 31 do not include tapered edges. FIG. 6 b shows a lower leftperspective view of the clip 31 while FIG. 6 c shows an upper rightperspective view of the clip 31.

In yet another example, FIG. 7 a illustrates another embodiment of theinventive clip wherein a clip 41 is used for roof that is on a 7/12pitch. A difference between the clip 21 of FIG. 5 a and the clip ofFIGS. 7 a-c is the pitch. Also, the size of the clip 41 can alsopossible be different or the same relative to the clip 21 in FIGS. 5a-c. Moreover, each of the lower left and right flanges 44 and 45includes a tapered edge 44 a and 45 a, respectively, to facilitate beingbent by the break press or machine. FIG. 7 b shows a lower leftperspective view of the clip 41 while FIG. 7 c shows an upper rightperspective view of the clip 41 wherein the upper left and right flanges42 and 43 are shown.

Similarly, in yet another example, FIG. 8 a illustrates anotherembodiment of the inventive clip wherein a 7/12 hip and valley clip 51is used for roof that is on a 7/12 pitch. A difference between the clip51 and the clip 31 of FIGS. 6 a-c is the pitch. Also, the size of theclip 51 may be different or the same as the size of the clip 31 in FIGS.6 a-c. Moreover, as in FIG. 6 a, the lower left and right flanges 54 and55 of the clip 51 include relatively smaller tapered surfaces 54 a and55 a, respectively, compared with the tapered surfaces 44 a and 45 a ofthe clip 41. FIG. 8 b shows a lower left perspective view of the clip 51while FIG. 8 c shows an upper right perspective view of the clip 51wherein the upper left and right flanges 52 and 53 are shown.

FIG. 9 a illustrates another embodiment of the inventive clip 61 whereinthe clip 61 is used for a roof that has an 8/12 pitch. Similarly, FIG.10 a illustrates yet another embodiment of the inventive clip 71 whereina, 8/12 hip and valley clip 71 is used for a roof that has an 8/12pitch. Like the clips 21 and 41, the lower left and right flanges 64 and65, and 74 and 75, of the clips 61 and 71, respectively, include taperedsurfaces 64 a and 65 a, and 74 a and 75 a, respectively. As in the clips21 and 41, each of the lower left and right flanges 64 and 65 and 74 and75m of the clips 61 and 71, respectively, includes a tapered edge 64 aand 65 a, and 74 a and 75 a, respectively, to facilitate being bent bythe break press or machine. FIGS. 9 b and 10 show a lower leftperspective views of the clips 61 and 71, respectively, while FIGS. 9 cand 10 c show an upper right perspective view of the clips 61 and 71,respectively.

Although not illustrated herein, it is also within the scope of theinvention for the hip and valley clips 51 and 71 shown in FIGS. 8 a-cand 10 a-c to be manufactured for roofs having a pitch of 9/12, 10/12and 11/12. Such clips for the9/12, 10/12 and 11/12 pitch roofs willgenerally have the same structural configuration as the clips 51 and 71,with proper allowances for the size of the tapered edges and flanges tovary due to the different pitch for which each clip is manufactured.

FIGS. 11-14 show clips 81, 91, 101 and 111, respectively, that aremanufactured for roofs having a 9/12, 10/12, 11/12 and 12/12 pitch,respectively. The upper left and right flanges (82 and 83, 92 and 93,102 and 103, and 112 and 113, respectively) include flanges 82 a, 83 a,92 a, 93 a, 102 a, 103 a, 112 a and 113 a, respectively. Similarly, thelower left and right flanges (84 and 85, 94 and 95, 104 and 105, and 114and 115, respectively) include flanges 84 a and 85 a, 94 a and 95 a, 104a and 105 a, and 114 a and 115 a, respectively. The only differencebetween each of the clips 81, 91, 101 and 111 is the size of theircorresponding flanges, which is driven by the different roof pitch forwhich they are constructed. Although not illustrated, the flanges 82through 84 for the clip 81, the flanges 92 through 94 for the clip 91,the flanges 102 through 104 for the clip 101, and the flanges 112through 114 for the clip 111 are all bent away from the first surface 2in a manner similar to the previously described clips, and suchdiscussion is therefore omitted herefrom to avoid redundancy. Likewise,the tracks TR1 and TR2 are attached to the face of the lower left andright flanges for each of the clips 81, 91, 101 and 111 as describedabove.

As noted above, each of the aforementioned clips are preferablymanufactured from galvanized steel sheets of a light gauge, e.g., 16gauge, having a G-90 coating on at least one, and preferably both sides.The flanges of each clip described herein serve as attachment faces towhich the tracks TR1 and TR2 of the roofing system are attached tocreate a roof assembly. More importantly, and as illustrated by thedifferent embodiments shown and described above, is the fact that theinventive clip can be designed to fit the pitch of any roof, such thatthe larger the roof, the larger the size of the clip. In other words,the dimensions of the clip of the present invention are proportionalrelative to the pitch of the roof. As a result, the inventive clipeliminates not only the costly and time consuming step of cutting therafter to the precise angle of the roof pitch, but also substantiallyreduces the number of clips that must be used in the roofing assembly.Accordingly, the clip of the present invention provides or creates thepitch needed by the builder so that the builder may use the materials,e.g., rafters, tracks, and the like, as provided by the manufacturerwithout any further modifications made to the materials in the field. Assuch, the clip of the present invention saves the builder a significantamount of time spent on erecting or constructing the roof.

While there has been described herein what are at present considered tobe preferred embodiments of the present invention, it will be understoodthat various modifications may be made thereto, and it is intended thatthe appended claims cover all such modifications as fall within thespirit and scope or the present invention.

1. A clip to be used with at least one track in a roofing assembly, theclip comprising: a planar surface; and at least one pair of flangesextending away from the planar surface in an orthogonal manner to definea right angle between each flange and the planar surface, wherein eachflange defines an attachment surface for a corresponding track.
 2. Theclip according to claim 1, wherein each flange includes a tapered edge.3. The clip according to claim 1, wherein the planar surface has apentagon shaped geometric configuration.
 4. The clip according to claim3, wherein the at least one pair of flanges define a lower pair offlanges, each flange of the lower pair of flanges extending from a lowerboundary of the planar surface.
 5. The clip according to claim 4,wherein the planar surface further comprises an upper boundary, andwherein an upper pair of flanges extends away from the upper boundary ofthe planar surface in an orthogonal manner to define a right anglebetween each flange of the upper pair of flanges and the planar surface.6. The clip according to claim 5, wherein each flange of the upper pairof flanges includes a tapered edge.
 7. The clip according to claim 1,wherein the clip is sized to form a roof assembly having a pitchselected from any one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12.8. The clip according to claim 2, wherein the clip is sized to form aroof assembly having a pitch selected from any one of 6/12, 7/12, 8/12,9/12, 10/12, 11/12 and 12/12.
 9. The clip according to claim 5, whereinthe clip is sized to form a roof assembly having a pitch selected fromany one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12.
 10. The clipaccording to claim 6, wherein the clip is sized to form a roof assemblyhaving a pitch selected from any one of 6/12, 7/12, 8/12, 9/12, 10/12,11/12 and 12/12.
 11. The clip according to claim 1, wherein the planarsurface includes a G-90 coating and the clip is manufactured from one of16 gauge steel, wood, polymer and an alloy.
 12. The clip according toclaim 2, wherein the planar surface includes a G-90 coating and the clipis manufactured from one of 16 gauge steel, wood, polymer and an alloy.13. The clip according to claim 5, wherein the planar surface includes aG-90 coating and the clip is manufactured from one of 16 gauge steel,wood, polymer and an alloy.
 14. The clip according to claim 6, whereinthe planar surface includes a G-90 coating and the clip is manufacturedfrom one of 16 gauge steel, wood, polymer and an alloy.